CHAPTER 10 POWER TONGS

CONTENTS

INTRODUCTION .................................................................................................................... 3
POWER TONGS .................................................................................................................... 3
MANUAL BACKUP TONGS ...................................................................................................3
INTEGRAL TONGS................................ ................................ ................................ ................ 3
ADVANTAGES OF INTEGRAL TONGS .................................................................................. 4
TORQUE IS APPLIED DIRECTLY TO THE TUBULAR CONNECTION.................................4
INTEGRAL TONGS DO NOT DAMAGE PIPE......................................................................4
BACKUP LINES ARE NOT REQUIRED .............................................................................. 4
INTEGRAL TONGS CAN SHORTEN MAKE UP TIMES ....................................................... 4
TUBING COLLARS ARE NOT ACCIDENTALLY CRUSHED................................ ................ 4
PIPE WILL NOT TURN IN THE SLIPS ................................ ................................ ................ 4
INTEGRAL TONGS ALIGN PIPE PRECISELY....................................................................4
TORQUE IS GAUGED ACCURATELY................................ ................................ ................ 4
GRIPPING SYSTEM IS SENSITIVE AND ACCURATE................................ ........................ 4
FREE-FLOATING BACK-UP TONGS ..................................................................................... 4
PURE TORQUE................................................................................................................. 5
MINIMAL DIE DAMAGE .....................................................................................................5
NO NEED FOR BACK-UP LINES ....................................................................................... 5
SHORTER MAKE-UP AND BACK-OUT TIMES ...................................................................5
NO COLLAR CRUSHING ...................................................................................................5
GREATER ACCURACY OF TORQUE TURN COMPUTER MONITORING SYSTEMS ...........5
CORRECT ALIGNMENT ....................................................................................................5
ACCURATE LOAD CELLS.................................................................................................5
ACCURATE AND SENSITIVE GRIPPING SYSTEM ............................................................. 5
TONG PARTS................................ ................................ ................................ ........................ 5
4-WAY VALVES................................................................................................................. 6
HYDRAULIC MOTOR......................................................................................................... 6
LIFT CYLINDER................................................................................................................. 6
TONG BODY ..................................................................................................................... 6
GEARBOX......................................................................................................................... 6
ROTOR .............................................................................................................................. 7
DIES ..................................................................................................................................7
JAWS................................ ................................ ................................ ................................ 7
ROLLER............................................................................................................................ 7

Tubular Running Services Technician’s Manual - Chapter 10 rev 0 1 of 11

CHAPTER 10 POWER TONGS

BRAKING SYSTEM ...........................................................................................................7

TORQUE GAUGE ASSEMBLY........................................................................................... 7
PRESSURE GAUGE ..........................................................................................................8
HANGER SPRING ............................................................................................................. 8
“A” FRAME....................................................................................................................... 8
POWER TONG CONFIGURATIONS ....................................................................................... 8
CLOSED ROTOR............................................................................................................... 8
Advantages: .................................................................................................................. 9
Disadvantages: ............................................................................................................. 9
OPEN ROTOR ................................................................................................................... 9
Advantages: .................................................................................................................. 9
Disadvantages: ........................................................................................................... 10
GATED ROTOR............................................................................................................... 10
Advantages: ................................................................................................................ 10
Disadvantages: ........................................................................................................... 10
16-INCH AND 24- INCH ROTORS .................................................................................... 10

Tubular Running Services Technician’s Manual - Chapter 10 rev 0 2 of 11

CHAPTER 10 POWER TONGS

INTRODUCTION
Tongs are devices that are used to make up and break out tubular connections. The basic power
tong is used in conjunction with the manual backup tong. The integral power tong combines the
functions of the backup and power tongs into a single unit.

Note: The term power tong used in this manual refers only to power tongs and/or integral tongs,
not manual backup tongs.

POWER TONGS
Power tongs rotate the pin end of a threaded connection into the box end of another pipe in the
string. They are also used to break out threaded connections. Power tongs employ a snub line
that is attached to the rig. The snub line prevents the tong from rotating around the pipe.

MANUAL BACKUP TONGS

As the first (or last) few joints of a string are made up (or broken out), the string is not heavy
enough to provide sufficient rotation resistance for a power tong to work properly. The tong spins
the entire string and the threaded connection cannot make up. Manual backup tongs are
employed to provide the necessary rotation resistance during the first (or last) few joints. Manual
backup tongs do not spin. They are designed to hold the string in place as the power tong is used
to make up (or break out) the threaded connection. Manual backup tongs are much smaller than
regular power tongs because they do not have any hydraulic parts. They consist of:
• a body that is manufactured to a specific handle length
• interchangeable jaws that are manufactured to fit specific pipe sizes.
The manual backup tong also employs a snub line that is attached to the rig. The snub line
prevents the manual backup tong from rotating around the pipe.

INTEGRAL TONGS
The integral tong is a single unit that performs all the functions of a power tong and a manual
backup tong. The top part of an integral tong is the same in design and function as a power tong,
but the backup tong assembly that is suspended from the body of the unit is different from a
manual backup tong. The jaws of integral backup tongs are hydraulically powered. Because of
the backup tong assembly, the integral tong does not require a snub line; however, a safety line
should be attached to prevent the integral tong from rotating around the pipe if the backup tong
fails to grip.

Tubular Running Services Technician’s Manual - Chapter 10 rev 0 3 of 11

CHAPTER 10 POWER TONGS

ADVANTAGES OF INTEGRAL TONGS

The use of integral tongs with free-floating hydraulic backup assemblies continues to increase,
especially with chromium tubulars and premium threaded connections. This is because integral
tongs have several advantages over power tongs and manual backup tongs.
TORQUE IS APPLIED DIRECTLY TO THE TUBULAR CONNECTION
When forces are applied incorrectly to the pipe, crushing, bending, and/or grooving of the pipe
may occur at the slips. Applying force incorrectly may also cause threads to gall and parts of the
tong to fail prematurely. Integral tongs do not have this problem because they are capable of
applying torque directly to the tubular connection.
INTEGRAL TONGS DO NOT DAMAGE PIPE
Evenly spaced and loaded dies and a pressure release valve minimize damage and pipe
marking.
BACKUP LINES ARE NOT REQUIRED
Although safety lines are recommended, backup lines are not required to restrain the tong.
Operators can quickly orient integral tongs around the pipe in any position.
INTEGRAL TONGS CAN SHORTEN MAKE UP TIMES
The controls and the hydraulics for the free-floating backup are conveniently located on the
integral tong, so make up (and break out) operations are simpler and quicker. In addition, delays
that occur as a result of maneuvering and setting manual tongs are eliminated.
TUBING COLLARS ARE NOT ACCIDENTALLY CRUSHED
Manual tongs often crush tubing collars if they are accidentally closed around them. This is
because the jaws of a manual backup are preset to grip the smaller diameter of the pipe body.
Integral tongs with free-floating hydraulic backups do not crush tubing collars because the jaws
are not preset to grip a specific diameter pipe.
PIPE WILL NOT TURN IN THE SLIPS
Torque turn equipment does not work properly if the pipe rotates in the slips. Integral tongs with
free-floating hydraulic backups grip the pipe so that it cannot rotate.
INTEGRAL TONGS ALIGN PIPE PRECISELY
Integral tongs with free-floating hydraulic backups align pipe precisely for stabbing operations.
This reduces galling and cross threading that can occur when pipes are aligned manually.
TORQUE IS GAUGED ACCURATELY
Since the load cell is built into the body of the integral tong, it is not necessary to position it
perpendicular to the snub line for it to gauge torque accurately.
GRIPPING SYSTEM IS SENSITIVE AND ACCURATE
The integral tong is equipped with a sensitive and accurate gripping system that directs the make
up forces across the connection rather than producing bending and shearing forces.

FREE-FLOATING BACK-UP TONGS

Free -floating back-up tongs are designed to be self-reactive with the power tong to which they are
fitted, making conventional back-up lines unnecessary. These tongs have unique and patented
gripping systems that ensure the tubing is gripped by equally spaced and evenly loaded dies.
Because the dies are hydraulically loaded onto the pipe, it is possible to adjust the load to give
minimum marking compatible with torque requirements and grade of tubing. Each set of jaws or
die holder inserts is capable of griping pipe within a half-inch diameter tolerance range without die
changes.

Tubular Running Services Technician’s Manual - Chapter 10 rev 0 4 of 11

CHAPTER 10 POWER TONGS

PURE TORQUE
Pure torque is applied to the tubular connection. This eliminates shear force, preventing crushing,
bending, grooving, galling, or the premature failure of tong dies, rotaries, the rotary guide, or the
rollers.
MINIMAL DIE DAMAGE
The patented gripping system employs equally spaced dies that are hydraulically forced onto the
pipe, ensuring even loading and positive grip before pipe rotation. A pressure control valve allows
adjustment of the jaw gripping load to suit all combinations of tubular diameter and torque
requirements for various grades of pipe, minimizing pipe marking.
NO NEED FOR BACK-UP LINES
Traditional Back-up Lines are no longer necessary to restrain the tong from rotating around the
pipe, or as a point of measure for the Torque readings . The tong can be oriented in any direction
around the pipe, eliminating inaccuracies in torque readings caused by the back-up line not being
able to be at 90° to the tong.

NOTE: There must always be a safety line attached, to stop the tong rotating around the pipe in
the unlikely event of the back-up failing to grip.
SHORTER MAKE-UP AND BACK-OUT TIMES
Controls for the back-up assembly are built onto the tong and its hydraulicsystem, creating
simplicity of operation and shorter make-up times. Ahydraulic back-up eliminates delays in getting
the manual back-up tong togrip when backing out the connection.
NO COLLAR CRUSHING
Manual tongs often crush small tubing collars because their jaws are notdesigned for this
application.
GREATER ACCURACY OF TORQUE TURN COMPUTER MONITORING SYSTEMS
Hydraulic back-ups eliminate the turning of the lower joint in the slips.
CORRECT ALIGNMENT
Tongs with hydraulic back-ups assist in aligning joints correctly, cutting down on galling and cross
threading problems.
ACCURATE LOAD CELLS
Accurate torque readings can be obtained because the load cells are mounted on the tongs, not
on the back-up line.
ACCURATE AND SENSITIVE GRIPPING SYST EM
The gripping system of the 5.5 tong with hydraulic back-up is so accurate that it is being used
successfully for the make-up of fiberglass pipe that is particularly susceptible to cracking.

TONG PARTS
The hydraulic power unit supplies power tongs with a high-pressure supply line and a low
pressure return line. Pipework connects the components in the power tong that complete the
hydraulic circuit, including the:
• 4-way valves
• hydraulic motor
• lift cylinder.
The power tong is also made up of other components, such as the:

Tubular Running Services Technician’s Manual - Chapter 10 rev 0 5 of 11

CHAPTER 10 POWER TONGS

• body
• gearbox
• rotor
• braking system
• roller
• jaws
• dies
• torque gauge assembly/pressure gauge
• hanger spring
• “A” frame.
Note: Integral power tongs have additional parts that are not listed or discussed here.
4-WAY VALVES
The 4-way valve is a direction control valve in the power tong’s hydraulic circuit. The power tong
operator uses this valve to control the flow of hydraulic fluid to the hydraulic motor in the power
tong. Depending on the position of this valve, the power tong rotor operates clockwise or
counterclockwise. When the valve is in the neutral position, the hydraulic fluid bypasses the motor
and flows through the low-pressure return line to the reservoir.

There is another 4-way valve on the power tong that controls the flow of hydraulic fluid to the lift
cylinder. Depending on the position of this valve, the lift cylinder extends or retracts to move the
power tong up and down. When the valve is in the neutral position, the power tong does not
move.
HYDRAULIC MOTOR
The hydraulic motor is a mechanical motor that converts the flow of hydraulic fluid into rotating
motion. After hydraulic fluid flows through the hydraulic motor, it exits through the pipework and
flows back to the reservoir to complete the hydraulic circuit.
LIFT CYLINDER
The lift cylinder is a hydraulic cylinder attached to the top of the “A” frame (see below). It uses the
flow of hydraulic fluid to extend or retract, which raises or lowers the power tong. The lift cylinder
allows the operator to position the power tong without having to change the power tong
suspension line.
TONG BODY
The body is also known as the casing. It is the frame or chassis of the power tong that protects
the operator from the moving parts inside. The body is strong enough to contain the extreme
forces generated by the hydraulic motor.
GEARBOX
The gearbox located in the body changes the ratio of power from the hydraulic motor to the rotor.
High gear produces one turn of the drive shaft for every turn of the hydraulic motor, and low gear
produces one turn of the drive shaft for every four turns of the hydraulic motor. During the initial
make up of tubular connections the gearbox is in high gear, which provides quick spin-in. When
increased torque is needed to complete the make up, the gearbox is switched to low gear. When
the string is broken out, the low gear provides the torque necessary to break the connection, then
the high gear is used to spin-out the pipe quickly.

Tubular Running Services Technician’s Manual - Chapter 10 rev 0 6 of 11

CHAPTER 10 POWER TONGS

ROTOR
The rotor carries the:
• dies
• jaws
• roller
• braking system
• jaw activating cam system.
The hydraulic motor turns the rotor, which enables the mechanisms on the rotor to grip the
tubular. After the tubular is gripped, the rotating rotor provides the necessary torque to make up
or break out the connection.
DIES
The dies are the gripping mechanism. They are the only part of the power tong that touches the
tubular. It is important to use the correct size and type of dies. There are specific dies for
standard pipe diameters, and some that are designed for odd size pipe. In addition, special
“MicroGrip” dies are designed for chromium tubulars. See MicroGrip Systems for Chromium
Tubulars in Chapter 15 for more information about MicroGrip dies.
JAWS
The jaws carry the dies that grip tubulars. No part of the jaw itself touches the pipe. Once the
jaws have engaged the pipe, they become self-energized and grip the pipe in proportion to the
applied forces. Jaws are shaped to fit standard pipe sizes. It is important to use the correct size
jaw; if incorrect sizes are used, the dies will not grip the tubular properly.
ROLLER
The roller moves along the decreasing inside diameter of the cam mechanism (an indentation on
the inside surface of the rotor), pushing the jaw into the tubular body. It is essential to use the
roller size that is specified for the diameter of pipe you are using. Incorrect sizes may:
• damage the pipe
• damage the power tong
• prevent the jaws from gripping the pipe properly.
Damage caused by using incorrect rollers may cause problems that are difficult to diagnose in the
field.
BRAKING SYSTEM
The braking system is a magnet or a mechanical device that functions in tandem with the roller,
the cam, and the master jaw to push the dies into proper gripping position during initial make up.
Specifically, the braking system prevents the jaws from turning with the rotor until the dies grip the
tubular properly. In magnetic braking systems, a magnet seated in the master jaw is attracted to
the power tong housing. The magnetic attraction keeps the jaws from turning as the rotor begins
to rotate. As the rotor rotates, the roller in the master jaw moves up the decreasing inside
diameter of the cam, which pushes the master jaw towards the tubular. The master jaw moves
the dies into proper gripping position. The magnetic attraction that prevents the jaws from rotating
is forcibly broken, and the jaws begin to rotate with the rotor.
TORQUE GAUGE ASSEMBLY
The power tong operator uses the torque gauge to determine how much torque the power tong is
exerting on the tubular connection.
The torque gauge assembly is a closed circuit hydraulic system. It consists of a:

Tubular Running Services Technician’s Manual - Chapter 10 rev 0 7 of 11

CHAPTER 10 POWER TONGS

• torque indicator
• sender unit (a hydraulic piston)
• flexible hose
• mounting assembly.
The solid end of the sender unit is attached to the power tong, and the piston end is attached to
the snub line, which is secured to the rig. As a connection is made up, the force exerted by the
power tong pulls the sender unit. The hydraulic pressure that the piston creates is transmitted
through the flexible hose to the gauge where it is converted from psi to foot-pounds. The torque
gauge will not give accurate readings unless the snub line and the torque gauge assembly
are level and are attached to the power tong at a 90º angle.
PRESSURE GAUGE
The pressure gauge is found on integral backup tongs and certain power tongs. On power tongs,
the pressure gauge serves as a torque gauge. To get an accurate torque measurement from a
pressure gauge on older units, operators must use a table to convert psi to foot-pounds. Newer
units are equipped with a gauge that is calibrated in foot-pounds and psi.
HANGER SPRING
The hanger spring permits the power tong to lower slightly during make up to compensate for
make up loss. The device resembles the coil springs from an automobile. The hanger spring is
suspended from a hanging derrick line, a rig winch line, or from other rig lines.
“A” FRAME
The “A” frame is fixed to the top of the power tong and provides attachment to the power tong
support line through the hanger springs and lift cylinder. It also houses the adjustment
mechanisms to level the power tong.

POWER TONG CONFIGURATIONS

Power tongs are available in three configurat ions based on the design of its rotor. The three
configurations include:
• closed rotor power tongs
• open rotor power tongs
• gated rotor power tongs.
Each of these rotor configurations has specific structural and operational characteristics, as well
as advantages and disadvantages. You should understand these aspects of each rotor
configuration so that you can provide the customer with information about the type of
configuration best suited for his needs.
CLOSED ROTOR
Closed rotor power tongs have a single piece rotary with no opening on the side of the rotor.
Tubulars are run through the top of the rotor. The jaw system must provide adequate retraction to
clear the tubulars and couplings that are passed through.

Tubular Running Services Technician’s Manual - Chapter 10 rev 0 8 of 11

CHAPTER 10 POWER TONGS

Advantages:
The jaw forces are distributed evenly because of the one-piece rotor. Even distribution of the
forces across the pipe minimizes the crushing damage that may occur with other rotor
configurations.
Disadvantages:
The jaws may not retract enough to provide adequate clearance for inserting the tubular into
position for make up. Inserting and positioning the tubular properly is an awkward procedure.
OPEN ROTOR
Open rotor power tongs have a single piece rotary and a rotor that is shaped like the letter “C.”
The open section allows the power tong to be moved on to the tubular from the side rather than
the top. Because of the shape of the rotor, the jaws do not have to retract as far as the jaws on a
closed rotor power tong to clear the tubular. Open rotor power tongs can use a variety of gripping
systems. The most common gripping system employs two jaws mounted to pivoting radial guides
on the rotor. This gripping mechanism allows the jaw cam linkage and the rotor to rotate (to a
limited degree) relative to each other.

Advantages:
The opening in the rotor makes it very easy to maneuver the power tong on and off the pipe.

Tubular Running Services Technician’s Manual - Chapter 10 rev 0 9 of 11

CHAPTER 10 POWER TONGS

Disadvantages:
The “C” shape of the rotor does not distribute the jaw forces across the pipe evenly. Using the
tong normally may eventually result in:
• damaged rotor bearings
• weakening of the rotor
• weakening of the tong body.
GATED ROTOR
Gated rotor power tongs have three-piece rotor that surrounds the tubular. The rotor opens so
that the power tong can be moved on and off the tubular easily. The three-piece rotor system
employs three jaws. The master or power jaw is attached to the rear segment of the rotor, and
each of the other two jaws is fixed to side sections. The two side sections pivot from the rear
section when the rotor is open and latch together when the rotor is closed. In gated rotor power
tongs, a drag system retards jaw motion, which causes the cam surface to push the master jaw
into the pipe. Costly damage to the rotor may result from broken plunger pins. If the plunger pin
that latches the sections of the rotor malfunctions, repair or replace it immediately.

Advantages:
Like the closed rotor power tong, the gated rotor configuration distributes the gripping forces
evenly across the tubular body. However, it is much easier to move on and off the string than a
closed rotor power tong.
Disadvantages:
The rotor in the gated rotor configuration is complicated, difficult, and costly to manufacture. The
three piece rotor is manufactured from one piece of steel that is matched to very high tolerances.
For this reason, the parts are not interchangeable between one rotor and another.
16-INCH AND 24- INCH ROTORS
The standard rotor size for the 16-25 gated power tong is 13 5/8 inches. However, the tong has a
16-inch rotor to use for larger size pipe. The 24 -50 gated power tong has a 24-inch rotor to use
when pipe size is greater than 20 inches. On both tongs, the reversing pin system is reversed
when you use the larger rotor, meaning that make-up is break-out and break-out is make-up. For
example, when using the 20-inch rotor on the 24-50 tong, the reversing pin slots through the
master jaw and lodges in the rotor. On the 24-inch rotor, the reversing pin lodges in the master
jaw through a cam activation slot attached to the rotor. This reversal is NOT noted on the rotor or
power tong body.

Tubular Running Services Technician’s Manual - Chapter 10 rev 0 10 of 11

CHAPTER 10 POWER TONGS

Tubular Running Services Technician’s Manual - Chapter 10 rev 0 11 of 11